Evolution of Large Fossil Fired

Turbo-generator

Hiromichi Ito
27 August, 2008

© TOSHIBA CORPORATION 2008, All Rights Reserved 1

 Topics presented and discussed

™ Experience and development history of 1000MW size generator

™ What drives the development of 1000MW size generator
™ The world’s largest 2-Pole, 50/60Hz, 1120MVA generator
™ Concept of turbo-generator in the next generation
™ Experience and development history of large capacity
indirectly hydrogen-cooled generator
™ The world’s largest 2-Pole, 50/60Hz, 700MVA class indirectly
hydrogen cooled generator
™ Hydrogen vs. water cooled generator
™ Summary

© TOSHIBA CORPORATION 2008, All Rights Reserved 2

 Growth in generator unit capacity

1,400
Generator unit capacity (MVA)

1,265
1,200 1,120

1,000 934 1,120

2p-60Hz 800 802

800 (3600rpm)
634.8 776
600
500
442 408
400 2p-50Hz
281 350 (3000rpm)
200 224
160
0
1940 1950 1960 1970 1980 1990 2000 2010

Production year
© TOSHIBA CORPORATION 2008, All Rights Reserved 3
 The world’s largest 2P-1000MW size generator

Hekinan #4 Taizhou #1
1265MVA
(Japan) (China)
Output (kW) 1,063 1,000 1,000(1,100)
Capacity (MVA) 1,265 1,120 1,120(1,230)
Voltage (V) 27,000 25,000 27,000
Current (A) 27,050 25,866 23,950(26,302)
Frequency (Hz) 60 60 50
Power factor 0.85 0.9 0.9
H2 pressure (kPag) 520 520 500
Temperature rise Class B Class B Class B
COD - 2001 2007

© TOSHIBA CORPORATION 2008, All Rights Reserved 4

 What drives the development of 1000MW size
generator

„ Evaluation for economy of larger thermal power plant

„ Lower initial cost and reduced plant space
„ Push for higher efficiency plant
„ Less maintenance and ease of operation
„ Turbine is comprised of multi-sections (HP-IP-LP)
„ A single machine is required for generator
„ Large high-speed rotating machine for thermal units
（Single rotor ）
„ Limitation in large rotor manufacturing
„ Reduction of machine (stator) size

© TOSHIBA CORPORATION 2008, All Rights Reserved 5

Employed technologies to 1,000MW class generator
P = K･Di2･L･n

Core end with High TS 4Ni-Cr Unequal section Improved coil end
flux shunt shaft forging mix strand water support
cooled stator
coil
High TS 18Mn-18Cr RR

Optimized L/D
rotor

Maximized field
conductor area

Center grooved
elliptical 2 piece babbitt Low Fn compact Hydrogen
journal bearing sealing ring frame cooled HVB

© TOSHIBA CORPORATION 2008, All Rights Reserved 6

 R & D issues for 1,000MW size generators

„ High strength and toughness large rotor shaft forging

Successfully developed a large size generator shaft
forging of min.1000MPa (145ksi) for TS
with comparable toughness to conventional ones.

„ High strength and toughness, and non-magnetic retaining

ring material
Successful development of 18%Mn-18%Cr non-magnetic
retaining ring material of min. 1300MPa (188ksi) for TS
with high SCC resistance

„ Compact stator structure

Introduction of new stator structure design concept with
a low natural frequency stator

© TOSHIBA CORPORATION 2008, All Rights Reserved 7

 Verification by a full size but short model rotor

- Same diameter as 1000MW rotor but

shorter rotor length
- Same materials and configuration as
1000MW rotor design

Short production size model rotor - Rotating tests including 120 % over
speed test
- Stress and displacement
measurements of over 100 points
- Start and stop operation test of 500
times
- Excitation tests simulating working
temperature rise
- Dismantling and inspections after
Verification tests rotating tests
© TOSHIBA CORPORATION 2008, All Rights Reserved 8
 2P, 60Hz, 1,000MW generator for
Chubu/Hekinan #4, #5

COD
#4 : Nov. 2001
#5 : Nov. 2002

© TOSHIBA CORPORATION 2008, All Rights Reserved 9

 2P, 50Hz, 1,000MW generator for
China/Taizhou #1

COD
#1 : Dec. 2007
#2 : Mar. 2008

© TOSHIBA CORPORATION 2008, All Rights Reserved 10

 Concept of turbo-generator in the next generation
New concept to the next generation

Voice
Voiceof
ofcustomers
customers Generator
Generatormanufacturers
manufacturers
­­ Low
Lowinitial
initialcost
cost ­­ Easy
Easy&&cost
costeffective
effective
­­ Short
Shortcycle
cycletime
time procurement
procurement
­­ Low
LowCO2
CO2emission
emission ­­ Easy
Easydesign
designand
andproduction
production
­­ Ease
Easeofofoperation
operation ­­ Short
Shortproduction
productiontime
time
­­ Low
Lowmaintenance
maintenancecostcost ­­ Machine
Machineintegrity
integrity
Low life time cost Simplified generator

Solution: Simplified cooled generator

Directly H2O/H2/Air cooled generator

Indirectly H2/Air cooled generator with innovative technology

© TOSHIBA CORPORATION 2008, All Rights Reserved 11

 Growth in generator unit capacity
Indirectly hydrogen-cooled generators
Generator unit capacity (MVA)

800

700
710
670
600 575
500
445
406
400 355 60Hz
323 326
300 290

200

100 50Hz
0
1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
Production year

© TOSHIBA CORPORATION 2008, All Rights Reserved 12

 The world’s largest indirectly hydrogen-cooled generators

60Hz 50Hz
Capacity (MVA) 670 575 710
Voltage (kV) 19 19.5 20.5
Current (A) 20,360 17,025 19,997
Rotating speed (rpm) 3,600 3,600 3,000
Power factor 0.9 0.85 0.85
H2 pressure (kPag) 520 412 412
Insulation class Class F Class F Class F
Temperature rise Class B Class B Class B
Production year (2008) 2002 2005

© TOSHIBA CORPORATION 2008, All Rights Reserved 13

 Remarkable increase in the output density

Output density : >150 %

as experienced
– HTC(High Thermal
Conductivity) stator
insulation >150
%
– Optimized gas flow
distribution in
ventilation circuit
– Increased hydrogen
gas pressure

Indirectly hydrogen cooled generators can supersede

water-cooled generators by innovative technologies.
© TOSHIBA CORPORATION 2008, All Rights Reserved 14
 Employed technologies to the developed generator

Innovative HTC Optimized gas Secured stator core

stator insulation flow distribution end structure

Improved stator
end winding
support structure

Radial flow
rotor cooling

Spring-plate Compact stator

Stable rotor dynamics frame
core support

© TOSHIBA CORPORATION 2008, All Rights Reserved 15

 Shop test results

Capacity 710MVA
Speed 3000 rpm
Power factor 0.85
Temp. rise B class
Test year 2005

Capacity 575MVA
Speed 3600 rpm
Power factor 0.85
Tem. rise B class
Test year 2002

© TOSHIBA CORPORATION 2008, All Rights Reserved 16

 Comparison between indirect hydrogen cooling
and direct water cooling
(A): Indirect hydrogen cooling (B): Direct water cooling

(A) (B)
Apparent power(MVA) 563.3 566
Power factor 0.9 0.9
Terminal voltage(kV) 20.5 19
Frequency(Hz) 50 50
Hydrogen pressure(kPag) 410 410
Rotor diameter & Same
Core length
Stator core outer diameter (pu) 1.09 1
Stator core volume (pu) 1.12 1
Efficiency (pu): test result 1.001 1

More volume, but higher efficiency

© TOSHIBA CORPORATION 2008, All Rights Reserved 17
 Summary
„ In recent years, there has been a growing tendency for
larger thermal units due to scale benefits.
„ In addition power market demands simple system from
the view point of ease operation and maintenance, and
higher efficiency as well.
„ To meet these requirements, the water-cooled 2-pole
1000MW size and indirectly hydrogen-cooled 2-pole
700MVA size generators have been developed.
„ Combination of high efficiency and compact design
technology has achieved both a reduction weigh and a
guaranty efficiency of 99.00%.

© TOSHIBA CORPORATION 2008, All Rights Reserved 18

 END of

Evolution of Large Fossil Fired

Turbo-generator

© TOSHIBA CORPORATION 2008, All Rights Reserved 19